Carrier PSD006-070, PSV, 50PSH User Manual

0 (0)

50PSH, PSV, PSD006-070

Single-Stage Water Source Heat Pumps

with PURON® Refrigerant (R-410A)

Installation, Start-Up, and

Service Instructions

AQUAZONE™

CONTENTS

Page

SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

Step 1 — Check Jobsite. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Step 2 — Check Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

• STORAGE

• PROTECTION

• INSPECT UNIT Step 3 — Locate Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

• FIELD CONVERSION OF DISCHARGE AIR Step 4 — Mount the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

• HORIZONTAL UNIT

• VERTICAL UNITS Step 5 — Check Duct System . . . . . . . . . . . . . . . . . . . . . . 9

• SOUND ATTENUATION

• EXISTING DUCT SYSTEM Step 6 — Install Condensate Drain . . . . . . . . . . . . . . . . . 9

• HORIZONTAL UNIT

• VERTICAL UNITS

• VENTING Step 7 — Pipe Connections . . . . . . . . . . . . . . . . . . . . . . . 10

• WATER LOOP APPLICATIONS

• GROUND-WATER APPLICATIONS

• GROUND-LOOP APPLICATIONS

• INSTALLATION OF SUPPLY AND RETURN HOSE KIT

Step 8 — Wire Field Power Supply . . . . . . . . . . . . . . . . 13

• POWER CONNECTION

• SUPPLY VOLTAGE

• 208-VOLT OPERATION

• 460-VOLT OPERATION

Step 9 — Wire Field Controls . . . . . . . . . . . . . . . . . . . . . 27

• THERMOSTAT CONNECTIONS

• WATER FREEZE PROTECTION

• AIR COIL FREEZE PROTECTION

• ACCESSORY CONNECTIONS

• WATER SOLENOID VALVES

• WSHP OPEN WIRING

Step 10 — Operate ECM Interface Board . . . . . . . . . . 29

• COOLING

• HEATING

• CFM ADJUST

• DEHUMIDIFICATION MODE

PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 System Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

FIELD SELECTABLE INPUTS . . . . . . . . . . . . . . . . . . 32-35 Complete C Control Jumper Settings . . . . . . . . . . . . . 32 Deluxe D Control Jumper Settings . . . . . . . . . . . . . . . . 32 Complete C Control DIP Switches. . . . . . . . . . . . . . . . . 32 Deluxe D Control DIP Switches . . . . . . . . . . . . . . . . . . . 32 Units with Modulating Hot Water Reheat

(HWR) Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Deluxe D Control Accessory

Relay Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Page

START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-42 Operating Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 Scroll Compressor Rotation. . . . . . . . . . . . . . . . . . . . . . .35 Unit Start-Up Cooling Mode . . . . . . . . . . . . . . . . . . . . . . .35 Unit Start-Up Heating Mode . . . . . . . . . . . . . . . . . . . . . . .36 Unit Start-Up with WSHP Open Controls . . . . . . . . . .40 Flow Regulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 Cooling Tower/Boiler Systems . . . . . . . . . . . . . . . . . . . .42 Ground Coupled, Closed Loop and Plateframe

Heat Exchanger Well Systems. . . . . . . . . . . . . . . . . . .42

OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-46 Power Up Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 Units with Aquazone Complete C Control . . . . . . . . .42 Units with Aquazone Deluxe D Control . . . . . . . . . . . .42 Units with HWR Option. . . . . . . . . . . . . . . . . . . . . . . . . . . .43 Units with WSHP Open Multiple Protocol. . . . . . . . . .43

COMPLETE C AND DELUXE D BOARD

SYSTEM TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46,47 Test Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 WSHP Open Test Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . .47 Retry Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 Aquazone Deluxe D Control LED Indicators . . . . . . .47

SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48,49 Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 Water Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 Condensate Drain Pans . . . . . . . . . . . . . . . . . . . . . . . . . . .48 Refrigerant System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 Fan Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 Condensate Drain Cleaning . . . . . . . . . . . . . . . . . . . . . . .48 Air Coil Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 Condenser Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 Checking System Charge . . . . . . . . . . . . . . . . . . . . . . . . .49 Refrigerant Charging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49 Air Coil Fan Motor Removal . . . . . . . . . . . . . . . . . . . . . . .49 Replacing the WSHP Open Controller’s

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49 TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . 49-57

Control Sensors Thermistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49 WSHP Open Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 Thermostatic Expansion Valves Stopped or Malfunctioned ECM Motor. . . . . . . . . . . . . 54 Moisture Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

APPENDIX A — WSHP OPEN SCREEN

CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-63 50PSH,PSV,PSD START-UP

CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . CL-1, CL-2

IMPORTANT: Read the entire instruction manual before starting installation.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

. . . . . . . . . . . . . . . . . . . 50

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

Catalog No. 04-53500055-01 Printed in U.S.A. Form 50PS-3SI Pg 1 7-09 Replaces: 50PS-2SI

SAFETY CONSIDERATIONS

Installation and servicing of air-conditioning equipment can be hazardous due to system pressure and electrical components. Only trained and qualified service personnel should install, repair, or service air-conditioning equipment.

Untrained personnel can perform basic maintenance functions such as cleaning coils and filters and replacing filters. All other operations should be performed by trained service personnel. When working on air-conditioning equipment, observe precautions in the literature, tags and labels attached to the unit, and other safety precautions that may apply.

Improper installation, adjustment, alteration, service, maintenance, or use can cause explosion, fire, electrical shock or other conditions which may cause personal injury or property damage. Consult a qualified installer, service agency, or a local distributor or branch for information or assistance. The qualified installer or agency must use factory-authorized kits or accessories when modifying this product. Refer to the individual instructions packaged with the kits or accessories when installing.

Follow all safety codes. Wear safety glasses and work gloves. Use quenching cloth for brazing operations. Have fire extinguisher available. Read these instructions thoroughly and follow all warnings or cautions attached to the unit. Consult local building codes and the National Electrical Code (NEC) for special installation requirements.

Understand the signal words — DANGER, WARNING, and CAUTION. DANGER identifies the most serious hazards which will result in severe personal injury or death. WARNING signifies hazards that could result in personal injury or death. CAUTION is used to identify unsafe practices, which would result in minor personal injury or product and property damage.

Recognize safety information. This is the safety-alert symbol ( ). When this symbol is displayed on the unit and in instructions or manuals, be alert to the potential for personal injury.

WARNING

Electrical shock can cause personal injury or death. Before installing or servicing system, always turn off main power to system. There may be more than one disconnect switch. Turn off accessory heater power if applicable.

Water source heat pumps (WSHPs) are single-package horizontally and vertically mounted units with electronic controls designed for year-round cooling and heating. Aquazone WSHPs are available in the following unit configurations:

• 50PSH unit with horizontal airflow and right, left or back

discharge

• 50PSV unit with vertical airflow and top discharge

• 50PSD unit with vertical airflow and bottom discharge

(downflow)

IMPORTANT: The installation of water source heat pump units and all associated components, parts, and accessories which make up the installation shall be in accordance with the regulations of ALL authorities having jurisdiction and MUST conform to all applicable codes. It is the responsibility of the installing contractor to determine and comply with ALL applicable codes and regulations.

INSTALLATION

Step 1 — Check Jobsite —

maintenance instructions are provided with each unit. Before unit start-up, read all manuals and become familiar with the unit and its operation. Thoroughly check out the system before operation. Complete the inspections and instructions listed below to prepare a unit for installation. See Table 1 for unit physical data.

IMPORTANT: This equipment is designed for indoor installation ONLY. Extreme variations in temperature, humidity and corrosive water or air will adversely affect the unit performance, reliability and service life.

HORIZONTAL UNIT (50PSH) —

ed for indoor installation only. Be sure to allow adequate space around the unit for servicing. Refer to Fig. 1 for an illustration of a typical horizontal installation. See Fig. 2 for overall unit dimensions.

VERTICAL AND DOWNFLOW UNITS (50PSV, PSD) — Vertical units are designed for indoor installations. While vertical units are typically installed in a floor-level closet or a small mechanical room, the unit access guidelines for these units are very similar to those described for horizontal units. See Fig. 3 and 4 for overall dimensions. Refer to Fig. 5 for an example of a typical vertical installation. Refer to Fig. 6 for a sample downflow installation.

Installation, operation and

Horizontal units are design-

GENERAL

This installation and start-up instructions literature is for

Aquazone™ single-stage water source heat pump systems.

CAUTION

To avoid equipment damage, do not use these units as a source of heating or cooling during the construction process. The mechanical components and filters used in these units quickly becomes clogged with construction dirt and debris which may cause system damage.

Table 1 — Physical Data — 50PSH, PSV, PSD018-070 Units

50PS UNIT SIZE 006* 009* 012* 018 024 030 036 042 048 060 070 COMPRESSOR (1 Each) Rotary Scroll FACTORY CHARGE R-410A (oz) 24 32 34 50 56 58 70 80 80 136 144 ECM FAN MOTOR AND BLOWER

Fan Motor (Hp) N/A N/A N/A Blower Wheel Size (D x W) (in.) N/A N/A N/A 9 x 7 9 x 7 9 x 7 11 x 10 11 x 10 11 x 10 11 x 10 11 x 10

PSC FAN MOTOR AND BLOWER (3 Speeds)

Fan Motor (Hp) High Static Fan Motor (Hp) N/A N/A N/A Blower Wheel Size (D x W) (in.) 6 x 5 6 x 5 6 x 5 9 x 7 9 x 7 9 x 7 10 x 10 10 x 10 10 x 10 11 x 10 11 x 10

Heat Exchanger Water Volume (gal.) 0.56 0.56 0.56 0.56 0.76 0.76 0.92 1.24 1.24 1.56 1.56 COAXIAL VOLUME (gal.) .17 .29 .45 .56 .76 .76 .92 1.24 1.24 1.56 1.56

WATER CONNECTION SIZE, FPT (in.)

HWG CONNECTION SIZE, FPT (in.) N/A N/A N/A

VERTICAL UPFLOW/DOWNFLOW

Air Coil Dimensions (H x W) (in.) 16 x 16 16 x 16 16 x 16 24 x 20 28 x 20 28 x 20 28 x 25 32 x 25 32 x 25 36 x 25 36 x 25

Throwaway Filter, Standard 1-in.,

Qty...Size 1...

Weight

Operating (lb) 126 146 150 252 266 268 327 414 416 441 443 Packag ed (lb) 136 156 160 262 276 278 337 424 426 451 453

HORIZONTAL

Air Coil Dimensions (H x W) (in.) 16 x 16 16 x 16 16 x 16 18 x 27 18 x 31 18 x 31 20 x 35 20 x 40 20 x 40 20 x 45 20 x 45

Throwaway Filter, Standard 1-in.,

Qty...Size 1...

Weight

Operating (lb) 136 156 160 257 266 268 327 414 416 441 443 Packag ed (lb) 146 166 170 267 276 278 337 424 426 451 453 Corner (lb)

Left Front 45.0 55.0 56.0 74.7 78.8 79.4 104.4 144.3 145.0 182.3 183.1 Left Rear 33.0 36.0 37.0 66.2 69.9 70.4 83.7 97.7 98.1 78.4 78.8 Right Front 30.0 33.0 34.0 63.6 67.2 67.7 74.9 92.1 92.6 72.5 72.8 Right Rear 28.0 32.0 33.0 47.5 50.2 50.5 64.0 79.9 80.3 107.8 108.3

ECM — Electronically Controlled Motor PSC — Permanent Split Capacitor FPT — Female Pipe Thread TXV — Thermostatic Expansion Valve HWG — Hot Water Generator

LEGEND *Unit sizes 006-012 not available on 50PSD unit.

16 x 20

1...

16 x 20

1...

16 x 20

1...

16 x 20

1...

16 x 20

1...

24 x 24

2...

18 x 18

1...

28 x 24

2...

18 x 18

NOTE: All units have spring compressor mountings, TXV expansion devices, and in. and 3/4-in. electrical knockouts.

1...

28 x 24

2...

18 x 18

1...

28 x 30

1...

12 x 20;

1...

20 x 25

1111

2...

16 x 30

1...

18 x 20;

1...

20 x 24

111

2...

16 x 30

1...

18 x 20;

1...

20 x 24

11 1N/A

1...

16 x 30;

20 x 30

20 x 24

1...

2...

16 x 30;

20 x 30

20 x 24

1...

2...

1..

/2-

Step 2 — Check Unit — Upon receipt of shipment at

the jobsite, carefully check the shipment against the bill of lading. Make sure all units have been received. Inspect the carton or crating of each unit, and inspect each unit for damage. Ensure the shipping company makes proper notation of any shortages or damage on all copies of the freight bill. Concealed damage not discovered during unloading must be reported to the shipping company within 15 days of receipt of shipment.

NOTE: It is the responsibility of the purchaser to file all necessary claims with the shipping company.

1. Be sure that the location chosen for unit installation provides ambient temperatures maintained above freezing. Well water applications are especially susceptible to freezing.

2. Be sure the installation location is isolated from sleeping areas, private offices and other acoustically sensitive spaces.

NOTE: A sound control accessory package may be used to help eliminate sound in sensitive spaces.

3. Check local codes to be sure a secondary drain pan is not required under the unit.

4. Be sure unit is mounted at a height sufficient to provide an adequate slope of the condensate lines. If an appropriate slope cannot be achieved, a field-supplied condensate pump may be required.

5. Provide sufficient space for duct connection. Do not allow the weight of the ductwork to rest on the unit.

6. Provide adequate clearance for filter replacement and drain pan cleaning. Do not allow piping, conduit, etc. to block filter access.

7. Provide sufficient access to allow maintenance and servicing of the fan and fan motor, compressor and coils. Removal of the entire unit from the closet should not be necessary.

8. Provide an unobstructed path to the unit within the closet or mechanical room. Space should be sufficient to allow removal of unit if necessary.

9. Provide ready access to water valves and fittings, and screwdriver access to unit side panels, discharge collar, and all electrical connections.

10. Where access to side panels is limited, pre-removal of the control box side mounting screws may be necessary for future servicing.

STORAGE — If the equipment is not needed immediately at the jobsite, it should be left in its shipping carton and stored in a clean, dry area of the building or in a warehouse. Units must be stored in an upright position at all times. If carton stacking is necessary, stack units a maximum of 3 high. Do not remove any equipment from its shipping package until it is needed for installation.

PROTECTION — Once the units are properly positioned on the jobsite, cover them with either a shipping carton, vinyl film, or an equivalent protective covering. Cap open ends of pipes stored on the jobsite. This precaution is especially important in areas where painting, plastering, or spraying of fireproof material, etc. is not yet complete. Foreign material that accumulates within the units can prevent proper start-up and necessitate costly clean-up operations.

Before installing any of the system components, be sure to examine each pipe, fitting, and valve, and remove any dirt or foreign material found in or on these components.

CAUTION

DO NOT store or install units in corrosive environments or in locations subject to temperature or humidity extremes (e.g., attics, garages, rooftops, etc.). Corrosive conditions and high temperature or humidity can significantly reduce performance, reliability, and service life. Always move units in an upright position. Tilting units on their sides may cause equipment damage.

INSPECT UNIT — To prepare the unit for installation, complete the procedures listed below:

1. Compare the electrical data on the unit nameplate with ordering and shipping information to verify that the correct unit has been shipped.

2. Do not remove the packaging until the unit is ready for installation.

Filter Access

Field-supplied transition to minimize pressure loss

Supply Air

Insulated supply duct with at least one 90 degree elbow to reduce air noise (field-supplied)

Flexible Connection

Field-Supplied Electric Heat (if applicable)

Aux Electric Heat Disconnect

Power Wiring

Unit Power Disconnect (by others)

Unit Hanger (factorysupplied)

3/8” threaded rods

(by others)

Return Air (Ductwork not shown)

Unit Power

3. Verify that the unit’s refrigerant tubing is free of kinks or dents, and that it does not touch other unit components.

4. Inspect all electrical connections. Be sure connections are clean and tight at their terminations.

5. Loosen compressor bolts until the compressor rides freely on springs. Remove shipping restraints.

6. Remove the four

/4 in. shipping bolts from compressor support plate (two bolts on each side) to maximize vibration and sound alternation.

CAUTION

Failure to remove shipping brackets from spring-mounted compressors will cause excessive noise and could cause component failure due to added vibration.

7. Remove any blower support cardboard from inlet of the blower.

8. Locate and verify any accessory kit located in compressor and/or blower section.

9. Remove any access panel screws that may be difficult to remove once unit is installed.

Thermostat

Wiring

Stainless steel braid hose with integral “J” swivel

(field-installed accessory)

Ball Valve with optional integral P/T plug (typical for supply and return piping)

Balancing Valve (fieldinstalled accessory)

Low Pressure Drop Water Control Valve (optional) (field-installed accessory)

Building

Loop

Water Out

Water In

(field-installed accessory)

3/8” Threaded

Rod (by others)

Vibration Isolator

(white-compressor end

and red-blower end)

Washer

(by others)

Double Hex Nuts

(by others)

Integral hanger supportpre-attached in factory

UNIT HANGER ISOLATION DETAIL

Fig. 1 — Typical Installation — 50PSH Unit

A50-7728

WATER CONNECTIONS

HWG

Out

(in.)

Con-

densate

Loop

Wate r

FPT

/2N/A N/A N/A 3.8 6.3 8.8 5.3 4.1 9.0 9.0 5.3 4.1 17.1 15.3 2.1 1.0

OVER ALL

50PSH

UNIT SIZE

006,009,

012

CABINET

(in.)

12 3 4 5

WidthBDepthCHeightDInEOut

22.4 43.1 17.3 3.7 9.7 N/A N/A 0.8

018 22.4 62.2 19.3 2.1 10.0 13.9 16.9 0.6

024,

22.4 62.2 19.3 2.1 10.0 13.9 16.9 0.63/

030

036 25.4 71.2 21.3 3.4 10.8 15.6 18.9 0.63/

042,

25.4 76.2 21.3 3.4 10.8 15.6 18.9 0.6 11/25.96 13.13 3.6 6.1 8.6 3.1 1.2 19.0 17.5 3.1 1.0 39.8 18.2 3.1 1.5

048

060,

25.4 81.2 21.3 3.4 10.8 15.6 18.9 0.6 11/25.96 13.13 3.6 6.1 8.6 3.1 1.2 19.0 17.5 3.1 1.0 44.8 18.2 3.1 1.5

070

NOTES:

1. Condensate is

2. Horizontal unit shipped with filter bracket only. This bracket should be removed for return duct connection.

3. Discharge flange and hanger kit is factory installed.

4. Shaded areas are recommended service areas, not required.

/4-in. FPT copper.

a50-8231

WATER

CONNECTIONS (in.) UNITS WITH

HWR

HWG

FPT

Loop

In D

Out E

/22.1 10.0 3.6 6.1 8.6 3.6 2.0 12.5 15.5 3.6 2.0 28.1 16.2 2.3 1.5

/25.26 13.13 3.6 6.1 8.6 3.6 2.0 12.5 15.5 3.6 2.0 33.8 16.2 2.3 1.5

/25.96 13.13 3.6 6.1 8.6 3.1 1.2 19.0 17.5 3.1 1.0 34.8 18.2 3.1 1.5

ASP — Alternate Service Panel BSP — Blower Service Panel CAP — Control Access Panel CSP — Compressor Service Panel FPT — Female Pipe Thread HWG — Hot Water Generator HWR — Hot Water Reheat LH — Left Hand RH — Right Hand

ELECTRICAL KNOCKOUTS

Cond

Low

Vol ta g e

LEGEND

(in.)

Cond

Ext

Pump

DISCHARGE CONNECTION (in.)

DUCT FLANGE INSTALLED

(±0.10 in.)

Cond

Power

Supply

(LH

rtrn)

Supply Height

Supply

Width

(RH

rtrn)

PSC BLOWER AIRFLOW

CONFIGURATION

CODE RETURN DISCHARGE

E Left Back B Right Back S Left Right Z Right Left

RETURN

CONNECTION (in.)

USING RETURN

AIR OPENING

(±0.10 in.)

Depth

T Return Height

Return

Fig. 2 — 50PSH Dimensional Data

WATER CONNECTIONS

HWG

Out

(in.)

Conden-

sate

Loop

Water

FPT

OVERALL

50PSV

UNIT SIZE

006,009,

012

018 22.4 25.6 44.6 2.1 10.0 13.9 16.9 7.83/

024,

030

036 25.4 30.6 50.5 3.4 10.8 15.6 18.9 7.83/

042,

048

060,

070

NOTES:

1. Condensate is 3/4-in. FPT copper and is switchable from side to front.

2. Vertical unit shipped with filter bracket only, extending from unit 2.5-in. This bracket should be removed for return duct connection.

3. Discharge flange field installed.

4. Shaded areas are recommended service areas, not required.

CABINET

(in.)

12 3 4 5

WidthBDepthCHeightDInEOut

22.4 21.6 34.5 3.7 9.7 N/A N/A 7.41/2N/A N/A N/A 3.8 6.3 8.8 6.7 6.3 9.0 9.0 6.7 2.3 17.1 15.3

22.4 25.6 48.5 2.1 10.0 13.9 16.9 7.83/

25.4 30.6 54.5 3.4 10.8 15.6 18.9 7.8 11/25.96 13.13 3.6 6.1 8.6 6.4 6.3 18.0 18.0 5.3 2.2 26.1 31.2

25.4 30.6 58.5 3.4 10.8 15.6 18.9 7.8 11/25.96 13.13 3.6 6.1 8.6 6.4 6.3 18.0 18.0 5.3 2.2 26.1 35.2

WATER

CONNECTIONS (in.) UNITS WITH

HWR

HWG

FPT

Loop

In D

Out E

/22.1 10.0 3.6 6.1 8.6 7.2 5.8 14.0 14.0 4.9 2.2 21.1 23.2

/25.26 13.13 3.6 6.1 8.6 7.2 5.8 14.0 14.0 4.9 2.2 21.1 27.2

/25.96 13.13 3.6 6.1 8.6 6.4 6.3 18.0 18.0 5.3 2.2 26.1 27.2

ELECTRICAL KNOCKOUTS

Cond

Low

Vol t ag e

LEGEND

(in.)

Cond

Ext

Pump

Cond

Powe r

Supply

DISCHARGE CONNECTION (in.)

DUCT FLANGE INSTALLED

(±0.10 in.)

(LH

rtrn)

Supply

Width

Supply

Depth

PSC BLOWER AIRFLOW

CONFIGURATION

CODE RETURN DISCHARGE

L Left Top R Right Top

(RH

rtrn)

RETURN

CONNECTION (in.)

USING RETURN

AIR OPENING

(±0.10 in.)

Return

Depth

Return

Height

1.0

R - Configuration Right Return / Top Discharge

- Top View

Right Return

- Air Coil Opening

- Right Side View

a50-8183

L - Configuration Left Return / Top Discharge

- Top View

Left Return

- Air Coil Opening

- Left Side View

Fig. 3 — 50PSV Dimensional Data

WATER CONNECTIONS

HWG

Out

(in.)

Conden-

sate

Loop

Wate r

FPT

OVERALL

50PSD

UNIT

SIZE

018 22.4 25.6 48.4 2.1 10.0 13.9 16.9 3.63/

024,

030

036 25.4 30.6 54.5 3.4 10.8 15.6 18.9 3.63/

042,

048

060,

070

NOTES:

1. Condensate is

2. Vertical unit shipped with filter bracket only, extending from unit 2.5-in. This bracket should be removed for return duct connection.

3. Downflow unit does not have discharge flange, and is rated for zero clearance installation.

4. Shaded areas are recommended service areas, not required.

CABINET

(in.)

12 3 4 5

WidthBDepthCHeightDInEOut

22.4 25.6 52.5 2.1 10.0 13.9 16.9 3.63/

25.4 30.6 58.5 3.4 10.8 15.6 18.9 3.6 11/25.96 13.13 3.6 6.1 8.6 7.2 9.0 13.4 12.9 10.4 2.2 26.1 31.2 1.0

25.4 30.6 62.5 3.4 10.8 15.6 18.9 3.6 11/25.96 13.13 3.6 6.1 8.6 7.2 9.0 13.4 12.9 10.4 2.2 26.1 35.2 1.0

/4-in. FPT copper and is switchable from side to front.

WATER

CONNECTIONS (in.) UNITS WITH

HWR

HWG

FPT

Loop

In D

Out E

/22.1 10.0 3.6 6.1 8.6 6.7 8.4 10.1 9.1 10.8 2.2 21.1 23.2 1.0

/25.96 13.13 3.6 6.1 8.6 6.7 8.4 10.1 9.1 10.8 2.2 21.1 27.2 1.0

/25.96 13.13 3.6 6.1 8.6 7.2 9.0 13.4 12.9 10.4 2.2 26.1 27.2 1.0

KNOCKOUTS

Cond

Low

Vol ta ge

LEGEND

ELECTRICAL

(in.)

Cond

Ext

Pump

Cond

Power

Supply

DISCHARGE CONNECTION (in.)

DUCT FLANGE INSTALLED

(±0.10 in.)

(LH

rtrn)

Supply

Width

CODE RETURN DISCHARGE

Supply

Depth

PSC BLOWER AIRFLOW

CONFIGURATION

L Left Bottom

R Right Bottom

Standard Filter Bracket

(RH

rtrn)

RETURN

CONNECTION (in.)

USING RETURN

AIR OPENING

(±0.10 in.)

Return

Depth

Return

Height

a50-7846ef

Blower

Opening

Front

Air Coil Side

Right Return / Bottom Discharge

ASP

Air Coil

Blower

Opening

Air Coil Side

Left Return / Bottom Discharge

1.1

CSP

2' Optional Service

Access Right Rtn

(left opposite)

Front

2' Service

Power Supply 3/4”

HV Knockout

1/2” Knockout

Low Voltage 1/2”

LV Knockout

Air Coil

Access

CSP

ASP

CAP

BSP

Condensate 3/4”

FPT

Isometric View

1.6

CAP

BSP

ASP

1.6

Front

Right Return Right View -

Air Coil Opening

Front

Condensate 3/4” FPT

Right Return

Condensate 3/4” FPT

Left Return

Front-View

Back

Left Return Left View -

Air Coil Opening

Fig. 4 — 50PSD Dimensional Data

Supply Air

Building

Flexible Connection

Return

Air

Power

Thermostat Wiring

Compressor Access Panel

A50-7730

NOTE: Ball valve with integral pressure temperature plug recommended.

Loop

Water Out

Water In

Stainless steel braid hose with integral “J” swivel (field-installed accessory)

integral P/T plug (typical for supply and return piping) (field-Installed accessory)

Control Valve (optional) (field-installed accessory)

Ball Valve with optional

Balancing Valve (field-installed accessory)

Low Pressure Drop Water

Fig. 5 — Typical Vertical Installation — 50PSV Unit

FIELD CONVERSION OF DISCHARGE AIR — The discharge air of the 50PSH horizontal units can be converted between side and back discharge in the field. The conversion process is the same for right and left return configurations. See Fig. 7 and 8.

NOTE: It is not possible to convert return air between left or right return models in the field due to refrigerant piping changes.

Water

Connection End

Side Discharge

Water

Connection End

Remove Screws

Return Air

Rotate

Return Air

Flexible Connection

Return

Air

Power

Thermostat

Wiring

Compressor Access Panel

A50-7729

NOTE: Ball valve with integral pressure temperature plug recommended.

Supply Air

Building Loop

Water

Out Stainless steel braid hose with integral ”J” swivel(fieldinstalled accessory)

Flexible

Connection

Water In

Balancing Valve

(field-installed

accessory)

Low Pressure Drop Water Control Valve (optional) (field-installed accessory)

Ball Valve with optional integral

P/T plug (typical for supply and return piping)(field-installed accessory)

Fig. 6 — Typical Downflow Installation —

50PSD Unit

Step 3 — Locate Unit — The following guidelines

should be considered when choosing a location for a WSHP:

• Units are for indoor use only.

• Locate in areas where ambient temperatures are between 39 F and 102 F and relative humidity is no greater than 75%.

• Provide sufficient space for water, electrical and duct connections.

• Locate unit in an area that allows easy access and removal of filter and access panels.

• Allow enough space for service personnel to perform maintenance.

• Return air must be able to freely enter the space if unit needs to be installed in a confined area such as a closet.

NOTE: Correct placement of the horizontal unit can play an important part in minimizing sound problems. Since ductwork is normally applied to these units, the unit can be placed so that the principal sound emission is outside the occupied space in sound-critical applications. A fire damper may be required by the local code if a fire wall is penetrated.

Connection End

A50-6256

Return Air

Drain

Discharge Air

Move to Side

Water

Back Discharge

Replace Screws

Fig. 7 — Conversion Left Return,

Side Discharge to Back Discharge

Return Air

Supply Duct

Side Discharge

Back Discharge

Connection End

Fig. 8 — Conversion Right Return, Side Discharge to Back Discharge

Return Air

Drain

Discharge Air

Water

Connection End

Water

A50-6257

Preparation

— The unit should be on the ground in a well lit area. Hung units should be taken down to ground level before converting.

Side to Back Discharge Conversion

1. Remove screws to free the top and discharge panels. Set screws aside for later use. See Fig. 7.

2. Remove the access panel and set aside.

3. Lift the discharge panel from side of unit and rotate it to back using care not to damage blower wiring.

4. Check blower wire routing and connections for undue tension or contact with sheet metal edges. Re-route if necessary.

5. Check refrigerant tubing for contact with other components. Adjust if necessary.

6. Reinstall top panel using screws set aside in Step 1. NOTE: Location for some screws at bottom of discharge

panel may have to be changed.

7. Manually spin fan wheel to check for obstructions. Adjust for any obstruction found.

8. Replace access panel.

Back to Side Discharge Conversion

— Follow instructions above for Side to Back Discharge Conversion, noting the panels would be reversed.

Step 4 — Mount the Unit

HORIZONTAL UNIT (50PSH) — Horizontal units should be mounted using the factory-installed hangers. Proper attachment of hanging rods to building structure is critical for safety. See Fig. 1. Rod attachments must be able to support the weight of the unit. See Table 1 for unit operating weights.

VERTICAL UNITS (50PSV, PSD) — Vertical and downflow units are available in left or right return air configurations. See Fig. 3 and 4. Mount the unit (except 50PSD) on a vibration absorption pad slightly larger than the entire base to minimize vibration transmission. It is not necessary to mount the unit on the floor. See Fig. 9.

NOTE: Some codes require the use of a secondary drain pan under vertical units. Check local codes for more information.

Step 5 — Check Duct System — Size the duct sys-

tem to handle the design airflow quietly. NOTE: Depending on the unit, the fan wheel may have a ship-

ping support installed at the factory. This must be removed before operating unit.

SOUND ATTENUATION — To eliminate the transfer of vibration to the duct system, a flexible connector is recommended for both discharge and return air duct connections on metal duct systems. The supply and return plenums should include internal duct liner of fiberglass or be made of duct board construction to maximize sound attenuation of the blower. Installing the WSHP unit to uninsulated ductwork in an unconditioned space is not recommended since it will sweat and adversely affect the unit’s performance.

To reduce air noise, at least one 90-degree elbow could be included in the supply and return air ducts, provided system performance is not adversely impacted. The blower speed can also be changed in the field to reduce air noise or excessive airflow, provided system performance is not adversely impacted.

EXISTING DUCT SYSTEM — If the unit is connected to existing ductwork, consider the following:

• Verify that the existing ducts have the proper capacity to

handle the unit airflow. If the ductwork is too small, install

larger ductwork.

• Check existing ductwork for leaks and repair as necessary.

NOTE: Local codes may require ventilation air to enter the

space for proper indoor air quality. Hard-duct ventilation

may be required for the ventilating air supply. If hard

ducted ventilation is not required, be sure that a proper air

path is provided for ventilation air to unit to meet ventila-

tion requirement of the space.

Step 6 — Install Condensate Drain

HORIZONTAL UNIT (50PSH) — Slope the unit toward the drain at quired pitch, install a condensate at the unit to pump condensate to building drain.

/4 in. See Fig. 10. If it is not possible to meet the re-

A50-7731ef

Fig. 9 — 50PSV Units Mounted With

Vibration Absorption Pad

1/4Ó Pitch for Drainage

Pitch Toward Drain

A50-6260

Drain Connection

Fig. 10 — Horizontal Unit Pitch

Horizontal units are not internally trapped, therefore an external trap is necessary. Install each unit with its own individual trap and means to flush or blow out the condensate drain line. Do not install units with a common trap or vent. See Fig. 11 for typical condensate connections.

NOTE: Never use a pipe size smaller than the connection.

A50-7732

NOTE: Trap should be deep enough to offset maximum unit static difference. A 4-in. trap is recommended.

Fig. 11 — Trap Condensate Drain Connection

VERTICAL UNITS (50PSV, PSD) — Each unit uses a condensate hose inside all cabinets as a trapping loop, therefore an external trap is not necessary. See Fig. 12.

Each unit must be installed with its own individual vent and means to flush or blow out the condensate drain line. Do not install units with a common trap or vent.

3/4” Copper FPT/PVC

1/2”

Water Connections

A50-6262

NOTE: Unit does not need to be sloped toward drain.

3/4” PVC Vent

Alternate Condensate Location

1/4” per foot slope to drain

1/2”

Fig. 12 — Vertical Condensate Connection

VENTING — Install a vent in the condensate line of any application that may allow dirt or air to collect in the line. Consider the following:

• Always install a vent where an application requires a long

horizontal run.

• Always install a vent where large units are working against

higher external static pressure and to allow proper drainage

for multiple units connected to the same condensate main.

• Be sure to support the line where anticipated sagging from

the condensate or when “double trapping” may occur.

• If condensate pump is present on unit, be sure drain connec-

tions have a check valve to prevent back flow of condensate

into other units.

Step 7 — Pipe Connections — Depending on the

application, there are 3 types of WSHP piping systems to choose from: water loop, ground-water and ground loop. Refer to Piping Section of Carrier System Design Manual for additional information.

All WSHP units use low temperature soldered female pipe thread fittings for water connections to prevent annealing and out-of-round leak problems which are typically associated with high temperature brazed connections. Refer to Table 1 for

connection sizes. When making piping connections, consider the following:

• Use a backup wrench when making screw connections to unit to prevent internal damage to piping.

• Insulation may be required on piping to avoid condensation in the case where fluid in loop piping operates at temperatures below dew point of adjacent air.

• Piping systems that contain steel pipes or fittings may be subject to galvanic corrosion. Dielectric fittings may be used to isolate the steel parts of the system to avoid galvanic corrosion.

WATER LOOP APPLICATIONS — Water loop applications usually include a number of units plumbed to a common piping system. Maintenance to any of these units can introduce air into the piping system. Therefore, air elimination equipment comprises a major portion of the mechanical room plumbing.

The flow rate is usually set between 2.25 and 3.5 gpm per

ton of cooling capacity. For proper maintenance and servicing, pressure-temperature (P/T) ports are necessary for temperature and flow verification.

Cooling tower/boiler systems typically utilize a common

loop maintained at 60 to 95 F. The use of a closed circuit evaporative cooling tower with a secondary heat exchange between the tower and the water loop is recommended. If an open type cooling tower is used continuously, chemical treatment and filtering will be necessary.

In addition to complying with any applicable codes, consid-

er the following for system piping:

• Piping systems using water temperatures below 50 F require

/2-in. closed cell insulation on all piping surfaces to

eliminate condensation.

• Avoid all plastic to metal threaded fittings due to the potential to leak. Use a flange fitted substitute.

• Teflon tape thread sealant is recommended to minimize internal fouling of the heat exchanger.

• Use backup wrench. Do not overtighten connections.

• Route piping to avoid service access areas to unit.

• Flush the piping system prior to operation to remove dirt and foreign materials from the system.

GROUND-WATER APPLICATIONS — Typical groundwater piping is shown in Fig. 13. In addition to complying with any applicable codes, consider the following for system piping:

• Install shut-off valves for servicing.

• Install pressure-temperature plugs to measure flow and temperature.

• Connect boiler drains and other valves using a “T” connector to allow acid flushing for the heat exchanger.

• Do not overtighten connections.

• Route piping to avoid service access areas to unit.

• Use PVC SCH80 or copper piping material.

NOTE: PVC SCH40 should not be used due to system high pressure and temperature extremes.

Water Supply and Quantity

— Check water supply. Water supply should be plentiful and of good quality. See Table 2 for water quality guidelines.

IMPORTANT: Failure to comply with the above required water quality and quantity limitations and the closedsystem application design requirements may cause damage to the tube-in-tube heat exchanger. This damage is not the responsibility of the manufacturer.

Table 2 — Water Quality Guidelines

CONDITION

Scaling Potential — Primary Measurement

Above the given limits, scaling is likely to occur. Scaling indexes should be calculated using the limits below.

pH/Calcium Hardness Method

Index Limits for Probable Scaling Situations (Operation outside these limits is not recommended.)

Scaling indexes should be calculated at 150 F for direct use and HWG applications, and at 90 F for indirect HX use. A monitoring plan should be implemented.

Ryznar Stability Index

Langelier Saturation Index

Iron Fouling

Iron Fe2+ (Ferrous) (Bacterial Iron Potential)

Iron Fouling

Corrosion Prevention††

Hydrogen Sulfide (H2S)

Ammonia Ion as Hydroxide, Chloride, Nitrate and Sulfate Compounds

Maximum Chloride Levels Maximum allowable at maximum water temperature.

Erosion and Clogging

Particulate Size and Erosion

Brackish

LEGEND

HWG — Hot Water Generator HX — Heat Exchanger N/A — Design Limits Not Applicable Considering Recirculating

NR — Application Not Recommended SS — Stainless Steel

*Heat exchanger materials considered are copper, cupronickel, 304 SS

(stainless steel), 316 SS, titanium.

†Closed recirculating system is identified by a closed pressurized piping

system.

**Recirculating open wells should obser ve the open recirculating design

considerations.

Potable Water

MATERIAL*

All N/A pH < 7.5 and Ca Hardness, <100 ppm

All N/A

All

All N/A

Copper N/A

Cupronickel N/A <150 ppm NR NR

304 SS N/A <400 ppm <250 ppm <150 ppm 316 SS N/A <1000 ppm <550 ppm <375 ppm

Titanium N/A >1000 ppm >550 ppm >375 ppm

All

All N/A

CLOSED

RECIRCULATING†

Monitor/treat as needed.

<10 ppm of particles and a maximum velocity of 6 fps.

6 - 8.5

Filtered for maximum

800 micron size.

OPEN LOOP AND RECIRCULATING WELL**

6.0 - 7.5

If >7.5 minimize steel pipe use.

–0.5 to +0.5

Based upon 150 F HWG and direct well, 85 F indirect well HX.

If Fe2+ (ferrous) >0.2 ppm with pH 6 - 8, O2<5 ppm check for iron bacteria.

Minimize steel pipe below 7 and no open tanks with pH <8.

At H2S>0.2 ppm, avoid use of copper and cupronickel piping of HXs.

Copper alloy (bronze or brass) cast components are okay to <0.5 ppm.

50 F (10 C) 75 F (24 C) 100 F (38 C)

<20 ppm NR NR

<10 ppm (<1 ppm “sandfree” for reinjection) of par ticles and a maximum velocity of 6 fps. Filtered for maximum 800 micron size. Any particulate that is not removed can potentially clog components.

Use cupronickel heat exchanger when concentrations of calcium or sodium chloride are greater than 125 ppm are present. (Seawater is approximately 25,000 ppm.)

††If the concentration of these corrosives exceeds the maximum allow-

able level, then the potential for serious corrosion problems exists. Sulfides in the water quickly oxidize when exposed to air, requiring that no agitation occur as the sample is taken. Unless tested immediately at the site, the sample will require stabilization with a few drops of one Molar zinc acetate solution, allowing accurate sulfide determination up to 24 hours after sampling. A low pH and high alkalinity cause system problems, even when both values are within ranges shown. The term pH refers to the acidity, basicity, or neutrality of the water supply. Below 7.0, the water is considered to be acidic. Above 7.0, water is considered to be basic. Neutral water contains a pH of 7.0. To convert ppm to grains per gallon, divide by 17. Hardness in mg/l is equivalent to ppm.

If <–0.5 minimize steel pipe use.

<0.2 ppm (Ferrous)

<0.5 ppm of Oxygen

Above this level deposition will occur.

6 - 8.5

<0.5 ppm

Rotten egg smell appears at 0.5 ppm level.

<0.5 ppm

In all applications, the quality of the water circulated through the heat exchanger must fall within the ranges listed in the Water Quality Guidelines table. Consult a local water firm, independent testing facility, or local water authority for specific recommendations to maintain water quality within the published limits.

GROUND-LOOP APPLICATIONS — Temperatures between 25 and 110 F and a cooling capacity of 2.25 to 3 gpm of flow per ton is recommended. In addition to complying with any applicable codes, consider the following for system piping:

• Limit piping materials to only polyethylene fusion in the

buried sections of the loop.

• Do not use galvanized or steel fittings at any time due to

corrosion.

• Avoid all plastic to metal threaded fittings due to the poten-

tial to leak. Use a flange fitted substitute.

• Do not overtighten connections.

• Route piping to avoid service access areas to unit.

• Use pressure-temperature (P/T) plugs to measure flow of

pressure drop. INSTALLATION OF SUPPLY AND RETURN HOSE

KIT — Follow these piping guidelines.

1. Install a drain valve at the base of each supply and return riser to facilitate system flushing.

2. Install shutoff/balancing valves and unions at each unit to permit unit removal for servicing.

3. Place strainers at the inlet of each system circulating pump.

4. Select the proper hose length to allow slack between connection points. Hoses may vary in length by +2% to –4% under pressure.

5. Refer to Table 3. Do not exceed the minimum bend radius for the hose selected. Exceeding the minimum bend radius may cause the hose to collapse, which reduces water flow rate. Install an angle adapter to avoid sharp bends in the hose when the radius falls below the required minimum.

NOTE: Piping must comply with all applicable codes.

Table 3 — Metal Hose Minimum Bend Radii

HOSE DIAMETER (in.) MINIMUM BEND RADII (in.)

21/

Insulation is not required on loop water piping except where the piping runs through unheated areas or outside the building or when the loop water temperature is below the minimum expected dew point of the pipe ambient. Insulation is required if loop water temperature drops below the dew point.

IMPORTANT: Do not bend or kink supply lines or hoses.

Pipe joint compound is not necessary when Teflon threaded tape is pre-applied to hose assemblies or when flared-end connections are used. If pipe joint compound is preferred, use compound only in small amounts on the male pipe threads of the fitting adapters. Prevent sealant from reaching the flared surfaces of the joint.

NOTE: When anti-freeze is used in the loop, assure that it is compatible with Teflon tape or pipe joint compound employed.

Maximum allowable torque for brass fittings is 30 ft-lb. If a torque wrench is not available, tighten finger-tight plus one quarter turn. Tighten steel fittings as necessary.

Water Control Valve (field-installed accessory)

Flow Regulator (field-installed accessory)

Boiler Drains (field-installed)

Pressure

Ta nk

Water Out

Shut-Off Valve (field-installed accessory)

Strainer (field-installed accessory) (16 to 20 mesh recommended for filter sediment)

Fig. 13 — Typical Ground-Water Piping Installation

A50-7733

Water In From Pump

Optional pressure-rated hose assemblies designed specifically for use with Carrier units are available. Similar hoses can be obtained from alternate suppliers. Supply and return hoses are fitted with swivel-joint fittings at one end to prevent kinking during installation.

CAUTION

Backup wrench is required when tightening water connections to prevent water line damage. Failure to use a backup wrench could result in equipment damage.

Refer to Fig. 14 for an illustration of a supply/return hose kit. Male adapters secure hose assemblies to the unit and risers. Install hose assemblies properly and check them regularly to avoid system failure and reduced service life.

Step 8 — Wire Field Power Supply

WARNING

To avoid possible injury or death due to electrical shock, open the power supply disconnect switch and secure it in an open position during installation.

CAUTION

Use only copper conductors for field-installed electrical wiring. Unit terminals are not designed to accept other types of conductors. Failure to use copper conductors could result in equipment damage.

All field-installed wiring, including the electrical ground, MUST comply with the National Electrical Code (NEC) as well as applicable local codes. In addition, all field wiring must conform to the Class II temperature limitations described in the NEC.

Refer to unit wiring diagrams Fig. 15-25 for a schematic of the field connections, which must be made by the installing (or electrical) contractor. Refer to Tables 4-6 for fuse sizes.

Consult the unit wiring diagram located on the inside of the compressor access panel to ensure proper electrical hookup. The installing (or electrical) contractor must make the field connections when using field-supplied disconnect.

Operating voltage must be the same voltage and phase as shown in electrical data shown in Tables 4-6.

Make all final electrical connections with a length of flexible conduit to minimize vibration and sound transmission to the building.

POWER CONNECTION — Make line voltage connection by connecting the incoming line voltage wires to the line side of the compressor contactor terminal as shown in Fig. 26. See Tables 4-6 for amperage ratings to provide correct wire and maximum overcurrent protection sizing.

SUPPLY VOLTAGE — Operating voltage to unit must be within voltage range indicated on unit nameplate.

On 3-phase units, voltages under load between phases must be balanced within 2%. Use the following formula to determine the percentage voltage imbalance:

% Voltage Imbalance

= 100 x

Example: Supply voltage is 460-3-60.

Determine maximum deviation from average voltage: (AB) 457 – 452 = 5 v

(BC) 464 – 457 = 7 v (AC) 457 – 455 = 2 v

Maximum deviation is 7 v. Determine percent voltage imbalance.

% Voltage Imbalance = 100 x

below the maximum allowable 2%.

imbalance constitutes abuse and may cause damage to electrical components.

NOTE: If more than 2% voltage imbalance is present, contact your local electric utility.

208-VOLT OPERATION — All 208-230 volt units are factory wired for 208 volts. The transformers may be switched to 230-volt operation by switching the red (208 volt) wire with the orange (230 volt) wire at the L1 terminal.

460-VOLT OPERATION — Units using 460-v and an ECM (electronically commutated motor) fan motor, modulating HWR, and/or internal secondary pump will require a neutral wire from the supply side in order to feed accessory with 265-v.

max voltage deviation from average voltage

average voltage

AB = 452 volts BC = 464 volts AC = 455 volts

Average Voltage =

= 1.53%

This amount of phase imbalance is satisfactory as it is

Operation on improper line voltage or excessive phase

452 + 464 + 455

1371

= 457

457

A50-7734

Swivel Brass

Rib Crimped

Fitting

Length

(2 ft Length Standard)

Fig. 14 — Supply/Return Hose Kit

Brass Fitting

MPT

LEGEND

AL — Alarm Relay Contacts ASTAT — Aquastat BR — Blower Relay CB — Circuit Breaker CC — Compressor Contactor CO — Condensate Overflow Sensor COMPR — Compressor DTS — Discharge Temp Switch FP1 — Water Coil Freeze Protection Sensor FP2 — Air Coil Freeze Protection Sensor HP — High-Pressure Switch HWG — Hot Water Generator JW — Jumper Wire LOC — Loss of Charge Pressure Switch MV — Motorized Valve NEC — National Electrical Code PSC — Permanent Split Capacitor P1 — Field Wiring Terminal Block RVS — Reversing Valve Solenoid

*Optional.

NOTES:

1. Compressor and blower motor thermally protected internally.

2. All wiring to the unit must comply with NEC and local codes.

3. 208/230 v transformer will be connected for 208 v operation. For 230 v operation, disconnect RED lead at L1 and attach ORANGE lead to L1. Insulate open end of RED lead. Transformer is energy limiting or may have circuit breaker.

4. FP1 thermistor provides freeze protection for water. When using antifreeze solutions, cut JW3 jumper.

5. Check installation wiring information for specific thermostat hookup. Refer to thermostat installation instructions for wiring to the unit. Thermostat wiring must be “Class 1” and voltage rating equal to or greater than unit supply voltage.

6. 24-v alarm signal shown. For dry alarm contact, cut JW1 jumper and dry contact will be available between AL1 and AL2.

7. Transformer secondary ground via Complete C board standoffs and screws to control box. (Ground available from top two standoffs as shown.)

8. Aquastat is supplied with unit and must be wired in series with the hot leg to the pump. Aquastat is rated for voltage up to 277 v.

9. Fan motors factory wired for medium speed. For high and low speed remove BLU wire from fan motor speed tap ‘M’ and connect to ‘H’ for high or ‘L’ for low.

TRANS — Transformer UPS — Unit Performance Sentinel

Solenoid Coil

Factory Low Voltage Wiring Factory Line Voltage Wiring Field Low Voltage Wiring Field Line Voltage Wiring Printed Circuit Trace Optional Wiring

Relay/Contactor Coil

Thermistor

Condensate Pan

Circuit Breaker

COMPLETE C CONTROLLER FAULT CODES

DESCRIPTION OF OPERATION LED ALARM RELAY

Normal Mode ON Open

Normal Mode with UPS Warning ON

Complete C is Non-Functional OFF Open Fault Retry Slow Flash Open Lockout Fast Flash Closed

Over/Under Voltage Shutdown Slow Flash

Test Mode-No Fault in Memory Flashing Code 1 Cycling Code 1 Test Mode-HP Fault in Memory Flashing Code 2 Cycling Code 2 Test Mode-LP Fault in Memory Flashing Code 3 Cycling Code 3 Test Mode-FP1 Fault in Memory Flashing Code 4 Cycling Code 4 Test Mode-FP2 Fault in Memory Flashing Code 5 Cycling Code 5 Test Mode-CO Fault in Memory Flashing Code 6 Cycling Code 6 Test Mode-Over/Under Shutdown

in Memory Test Mode-UPS in Memory Flashing Code 8 Cycling Code 8 Swapped FP1/FP2 Lockout Flashing Code 9 Cycling Code 9

Flashing Code 7 Cycling Code 7

Relay Contacts - N.C.

Relay Contacts - N.O.

Capacitor

Temperature Switch

Low Pressure Switch

High Pressure Switch

Wire Nut

Splice Cap

LED

Cycle (Closed 5 Sec.

Open 25 Sec.)

(Closed After 15 Min.)

Open

Fig. 15 — Units with Complete C Controller, Single-Phase

AL — Alarm Relay Contacts ASTAT — Aquastat BM — Blower Motor BMC — Blower Motor Capacitor BR — Blower Relay CB — Circuit Breaker CC — Compressor Contactor CO — Condensate Overflow Sensor COMPR — Compressor DTS — Discharge Temp Switch FP1 — Water Coil Freeze Protection Sensor FP2 — Air Coil Freeze Protection Sensor HP — High-Pressure Switch HWG — Hot Water Generator JW — Jumper Wire LOC — Loss of Charge Pressure Switch MV — Motorized Valve NEC — National Electric Code

*Optional.

NOTES:

1. Compressor and blower motor thermally protected inter nally.

2. All wiring to the unit must comply with NEC and local codes.

3. Transformer is wired to 460 v (BLK/RED) lead for 460/60/3 units, 575 v (GRY) lead for 575/60/3. Transformer is energy limiting or may have circuit breaker.

4. FP1 ther mistor provides freeze protection for water. When using antifreeze solutions, cut JW3 jumper.

6. 24-v alar m signal shown. For dry alarm contact, cut JW4 jumper and dry contact will be available between AL1 and AL2.

7. Transformer secondary ground via Deluxe D board standoffs and screws to control box. (Ground available from top two standoffs as shown.)

8. Aquastat is supplied with unit and must be wired in series with the hot leg to the pump. Aquastat is rated for voltage up to 277 v.

9. Blower motor is factory wired for high and low speeds. No other combination is available.

10. The 460-v units using an ECM (electronically commutated motor) fan motor, modulating HWR, and/or an internal secondary pump will require a neutral wire from the supply side in order to feed the accessory with 265-v.

TABLE 1 WIRE NUMBER

Blower Speeds

Factory

HI + MED

HI + LOW

MED + LOW

12345

BM(H) to

BR2(6)

BR2(3)

BM(R) to

BR2(3)

BM(R) to

BR2(3)

BM(R) to

BR2(3)

BM(M) to

BR2(7)

Not Used

BM(M) to

BR2(6)

Not Used

BM(L) to

BR2(7)

BM(L) to

BR2(7)

BR2(6) to

BR2(4)

BR2(6) to

BR2(4)

BR2(2) to

BR2(4)

LEGEND

P1 — Field Wiring Terminal Block RVS — Reversing Valve Solenoid TRANS — Transformer

Normal Mode ON OFF Note 2 Open Deluxe D is Non-Functional OFF OFF OFF Open Test Mode — ON Note 2 Cycle (Note 3) Night Setback Flashing Code 2 — Note 2 — Emergency Shut Down Flashing Code 3 — Note 2 — Invalid Thermostat Inputs Flashing Code 4 — Note 2 — No Fault in Memory ON OFF Flashing Code 1 Open

HP Fault/(Lockout) Note 1

LP Fault/(Lockout) Note 1

FP1 Fault/(Lockout) Note 1

FP2 Fault/(Lockout) Note 1

CC Fault/(Lockout) Note 1

Over-Under Voltage Slow Flash OFF Flashing Code 7 Open (Note 4) Normal Mode with UPS ON OFF Flashing Code 8 Cycle (Note 5) Swapped FP1/FP2 Lockout Fast Flash OFF Flashing Code 9 Closed

NOTES:

1. Status LED (GREEN) Slow Flash - Controller In - Fault Retry Mode. Fast Flash - Controller in Lockout Mode. Slow Flash = 1 Flash per every 2 seconds. Fast Flash = 2 Flashes per every 1 second.

2. Fault LED (RED) flashes a code representing last fault in memory. If no fault in memory code 1 is flashed.

3. Cycles appropriate code, by cycling alarm relay in the same sequence as fault LED.

4. Alarm relay closes after 15 minutes.

5. Alarm relay cycles. Closed for 5 seconds and open for 25 seconds.

Factory Low Voltage Wiring Factory Line Voltage Wiring Field Low Voltage Wiring Field Line Voltage Wiring Printed Circuit Trace Optional Wiring

Relay/Contactor Coil

Thermistor

Condensate Pan

Circuit Breaker

OPERATION

DELUXE D CONTROLLER FAULT CODES

STATUS LED

(GREEN)

Slow Flash/

(Fast Flash)

Slow Flash/

(Fast Flash)

Slow Flash/

(Fast Flash)

Slow Flash/

(Fast Flash)

Slow Flash/

(Fast Flash)

TEST LED (YELLOW)

OFF Flashing Code 2 Open/(Closed)

OFF Flashing Code 3 Open/(Closed)

OFF Flashing Code 4 Open/(Closed)

OFF Flashing Code 5 Open/(Closed)

OFF Flashing Code 6 Open/(Closed)

Ground

Solenoid Coil

Relay Contacts - N.C.

Relay Contacts - N.O.

Capacitor

Temperature Switch

Low Pressure Switch

High Pressure Switch

Wire Nut

Splice Cap

LED

FAULT LED

(RED)

ALARM

RELAY

Fig. 16 — Units with Deluxe D Controller, Three-Phase (460/575 V)

AL — Alarm Relay Contacts ASTAT — Aquastat BM — Blower Motor BR — Blower Relay CB — Circuit Breaker CC — Compressor Contactor CO — Condensate Overflow Sensor COMPR — Compressor DTS — Discharge Temp Switch ECM — Electronically Commutated Motor FP1 — Water Coil Freeze Protection Sensor FP2 — Air Coil Freeze Protection Sensor HP — High-Pressure Switch HWG — Hot Water Generator JW — Jumper Wire LOC — Loss of Charge Pressure Switch LWT — Leaving Water Temperature MV — Motorized Valve NEC — National Electric Code P1 — Field Wiring Terminal Block

*Optional.

LEGEND

RVS — Reversing Valve Solenoid TRANS — Transformer UPS — Unit Performance Sentinel

Factory Low Voltage Wiring Factory Line Voltage Wiring Field Low Voltage Wiring Field Line Voltage Wiring Printed Circuit Trace Optional Wiring

Relay/Contactor Coil

Thermistor

Condensate Pan

Circuit Breaker

Ground

Solenoid Coil

Relay Contacts - N.C.

Relay Contacts - N.O.

Capacitor

Temperature Switch

Low Pressure Switch

High Pressure Switch

Wire Nut

Splice Cap

LED

NOTES:

1. Compressor and blower motor thermally protected internally.

2. All wiring to the unit must comply with NEC and local codes.

4. FP1 thermistor provides freeze protection for water. When using antifreeze solutions, cut JW3 jumper.

6. 24-v alarm signal shown. For dry alarm contact, cut JW1 jumper and dry contact will be available between AL1 and AL2.

7. Transformer secondary ground via Complete C board standoffs and screws to control box. (Ground available from top two standoffs as shown.)

8. Aquastat is supplied with unit and must be wired in series with the hot leg to the pump. Aquastat is rated for voltage up to 277 v.

Fig. 17 — Units with Complete C ECM Blower, Three-Phase (208/230 V)

COMPLETE C CONTROLLER FAULT CODES

DESCRIPTION OF OPERATION LED ALARM RELAY

Normal Mode ON Open

Normal Mode with UPS Warning ON

Complete C is Non-Functional OFF Open Fault Retry Slow Flash Open Lockout Fast Flash Closed

Over/Under Voltage Shutdown Slow Flash

in Memory Test Mode-UPS in Memory Flashing Code 8 Cycling Code 8 Swapped FP1/FP2 Lockout Flashing Code 9 Cycling Code 9

Flashing Code 7 Cycling Code 7

Cycle (Closed 5 Sec.

Open 25 Sec.)

Open

(Closed After 15 Min.)

LEGEND

a50-8363

Complete C

AL — Alarm Relay Contacts ASTAT — Aquastat BM — Blower Motor BMC — Blower Motor Capacitor BR — Blower Relay CB — Circuit Breaker CC — Compressor Contactor CO — Sensor, Condensate Overflow DTS — Discharge Temperature Switch ECM — Electronically Commutated Motor FP1 — Sensor, Water Coil Freeze Protection FP2 — Sensor, Air Coil Freeze Protection HP — High-Pressure Switch HPWS — High-Pressure Water Switch HWG — Hot Water Generator JW1 — Clippable Field Selection Jumper LOC — Loss of Charge Pressure Switch LON — Local Operating Network MV — Motorized Valve MVES — Motorized Valve End Switch *Optional Wiring.

NOTES:

1. Compressor and blower motor thermally protected internally.

2. All wiring to the unit must comply with NEC and local codes.

3. Transformer is wired to 460 v (BLK/RED) lead for 460/3/60 units. Transformer is energy limiting or may have circuit breaker.

4. FP1 thermistor provides freeze protection for water. When using antifreeze solutions, cut JW3 jumper.

5. Typical thermostat wiring shown. Refer to thermostat installation instructions for wiring to the unit. Thermostat wiring must be Class 1 and voltage rating equal to or greater than unit supply voltage.

6. Factory cut JW1 jumper. Dry contact will be available between AL1 and AL2.

7. Transformer secondary ground via Complete C board standoffs and screws to control box. (Ground available from top two standoffs as shown.)

NEC — National Electrical Code P1 — Field Wiring Terminal Block RVS — Reversing Valve Solenoid TRANS — Transformer

Wire Nut

Relay Contacts - N.C.

Field Line Voltage Wiring Field Low Voltage Wiring Printed Circuit Trace Optional Wiring

Relay/Contactor Coil

Condensate Pan

Solenoid Coil

Temperature Switch

Thermistor

Ground

8. Aquastat is supplied with unit and must be wired in series with the hot leg to the pump. Aquastat is rated for voltages up to 277-v.

9. Optional LON wires. Only connect if LON connection is desired at the wall sensor.

10. Fan motors are factory wired for medium speed. For high or low speed, remove BLU wire from fan motor speed tap “M” and connect to “H” for high speed or “L” for low speed.

11. For low speed, remove BLK wire from BR “6” and replace with RED. Connect BLK and BRN wires together.

12. For blower motors with leads. For medium or low speed, disconnect BLK wire from BR “6”. Connect BLK and ORG/PUR wire together. Connect RED for low or BLU for medium to BR “6”.

13. The 460-v units using an ECM (electronically commutated motor) fan motor, modulating HWR (hot water reheat), and/or an internal secondary pump will require a neutral wire from the supply side in order to feed the accessory with 265-v.

Relay Contacts - N.O.

Low Pressure Switch

High Pressure Switch

Splice Cap

Circuit Breaker

Fig 18 — Units with ECM, Complete C and LON Controller (460 V)

LEGEND

Deluxe D

LOC

SEE NOTE 4

FP1

FP2

RVS

a50-8364

P1 — Field Wiring Terminal Block RVS — Reversing Valve Solenoid TRANS — Transformer

*Optional Wiring.

NOTES:

1. Compressor and blower motor thermally protected internally.

2. All wiring to the unit must comply with NEC and local codes.

3. Transformer is wired to 460 v (BLK/RED) lead for 460/3/60 units. Transformer is energy limiting or may have circuit breaker.

4. FP1 thermistor provides freeze protection for water. When using antifreeze solutions, cut JW3 jumper.

6. Factory cut JW1 jumper. Dry contact will be available between AL1 and AL2.

7. Transformer secondary ground via Deluxe D board standoffs and screws to control box. (Ground available from top two standoffs as shown.)

Wire Nut

Relay Contacts - N.C. Field Line Voltage Wiring Field Low Voltage Wiring Printed Circuit Trace Optional Wiring

Relay/Contactor Coil

Relay Contacts - N.O.

Low Pressure Switch

High Pressure Switch

Splice Cap

Circuit Breaker

Condensate Pan

Solenoid Coil

Temperature Switch

Thermistor

Ground

8. Aquastat is supplied with unit and must be wired in series with the hot leg to the pump. Aquastat is rated for voltages up to 277-v.

9. Blower motor is factory wired for medium and high speeds. For any other combination of speeds, at the motor attach the BLK wire to the higher of the two desired speed taps and the BLU wire to the lower of the two desired speed taps.

10. Optional LON wires. Only connect if LON connection is desired at the wall sensor.

11. Blower motor is factory wired for high and low speeds. No other combination is available.

12. The 460-v units using an ECM (electronically commutated motor) fan motor, modulating HWR (hot water reheat), and/or an internal secondary pump will require a neutral wire from the supply side in order to feed the accessory with 265-v.

Fig 19 — Units with ECM, Deluxe D and LON Controller (460 V)

LEGEND

a50-8232

AL — Alarm Relay Contacts ASTAT — Aquastat BM — Blower Motor BR — Blower Relay CB — Circuit Breaker CC — Compressor Contactor CO — Sensor, Condensate Overflow CR — Cooling Relay DTS — Discharge Temp Switch ECM — Electronically Commuted Motor FP1 — Sensor, Water Coil Freeze Protection FP2 — Sensor, Air Coil Freeze Protection HP — High Pressure Switch HPWS — High Pressure Water Switch HWG — Hot Water Generator JW — Jumper Wire LOC — Loss of Charge Pressure Switch LWT — Leaving Water Temperature MV — Motorized Valve MVES — Motorized Valve End Switch P1 — Field Wiring Terminal Block

RVS — Reversing Valve Solenoid SAT — Saturated Air Temperature TRANS — Transformer UPS — Unit Performance Sentinel

*Optional Wiring.

NOTES:

1. Compressor and blower motor thermally protected internally.

2. All wiring to the unit must comply with NEC and local codes.

3. 208-240 60 Hz units are wired for 208v operation. Transformer is energy limiting or may have circuit breaker.

4. FP1 thermistor provides low temperature protection for water. When using antifreeze solutions, cut JW3 jumper.

5. Refer to multiple protocol controller (MPC), LON, or TSTAT Installation, Application, and Operation Manual for control wiring to the wire from PremierLink controller to “Y” Complete C when motorized valve is not used. Thermostat wiring must be “Class 1” and voltage rating equal to or greater than unit supply voltage.

6. 24v alarm signal shown. For dry contact, cut JW1 jumper and dry contact will be available between AL1 and AL2.

7. Transformer secondary ground via green wire with yellow stripe from “C” terminal to control box.

8. Aquastat is supplied with unit and must be wired in series with the hot leg to the pump. Aquastat is rated for voltages up to 277v.

Thermistor

Ground

Field Line Voltage Wiring Field Low Voltage Wiring Field Line Voltage Wiring Field Low Voltage Wiring Printed Circuit Trace Optional Wiring

Relay/Contactor Coil

Condensate Pan

Solenoid Coil

Temperature Switch

COMPLETE C CONTROLLER FAULT CODES

DESCRIPTION OF OPERATION LED ALARM RELAY

Normal Mode ON Open

Normal Mode with UPS Warning ON

Complete C is Non-Functional OFF Open Fault Retry Slow Flash Open Lockout Fast Flash Closed Over/Under Voltage Shutdown Slow Flash Open (Closed After 15 Min.) Test Mode-No Fault in Memory Flashing Code 1 Cycling Code 1 Test Mode-HP Fault in Memory Flashing Code 2 Cycling Code 2 Test Mode-LP Fault in Memory Flashing Code 3 Cycling Code 3 Test Mode-FP1 Fault in Memory Flashing Code 4 Cycling Code 4 Test Mode-FP2 Fault in Memory Flashing Code 5 Cycling Code 5 Test Mode-CO Fault in Memory Flashing Code 6 Cycling Code 6 Test Mode-Over/Under Shutdown

in Memory Test Mode-UPS in Memory Flashing Code 8 Cycling Code 8 Swapped FP1/FP2 Lockout Flashing Code 9 Cycling Code 9

Flashing Code 7 Cycling Code 7

Wire Nut

Relay Contacts - N.C.

Relay Contacts - N.O.

Low Pressure Switch

High Pressure Switch

Splice Cap

Circuit Breaker

Capacitor

LED

Cycle (Closed 5 Sec.

Open 25 Sec.)

Fig. 20 — Units with Complete C and Premierlink™ Controller, Single-Phase (208/230 V)

Fig. 21 — Units with Complete C and WSHP Open Multiple Protocol Controls

WHSP-OPEN

A50-8355

LEGEND

BM — Blower Motor

BR — Blower Relay

CO — Condensate Overflow

LWT — Leaving Water Temperature

N.C. — Normally Closed

OAD — Outside Air Damper

OCC — Occupancy Input Contact

RH — Relative Humidity

SAT — Supply Air Temperature

SPT — Space Temperature

Fig. 22 — Units with Deluxe D and WSHP Open Multiple Protocol Controls

WSHP-OPEN

A50-8354

LEGEND

BM — Blower Motor

CO — Condensate Overflow

LWT — Leaving Water Temperature

N.C. — Normally Closed

OAD — Outside Air Damper

OCC — Occupancy Input Contact

RH — Relative Humidity

SAT — Supply Air Temperature

SPT — Space Temperature

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